CA2187013A1 - Method for forming plastic molded panels - Google Patents
Method for forming plastic molded panelsInfo
- Publication number
- CA2187013A1 CA2187013A1 CA002187013A CA2187013A CA2187013A1 CA 2187013 A1 CA2187013 A1 CA 2187013A1 CA 002187013 A CA002187013 A CA 002187013A CA 2187013 A CA2187013 A CA 2187013A CA 2187013 A1 CA2187013 A1 CA 2187013A1
- Authority
- CA
- Canada
- Prior art keywords
- blank
- panel
- cavity
- mold
- substrate
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 238000000034 method Methods 0.000 title claims abstract description 25
- 239000004033 plastic Substances 0.000 title claims abstract description 15
- 229920003023 plastic Polymers 0.000 title claims abstract description 15
- 239000000758 substrate Substances 0.000 claims abstract description 27
- 239000000463 material Substances 0.000 claims description 12
- 238000000465 moulding Methods 0.000 claims description 10
- 239000004744 fabric Substances 0.000 claims description 7
- 229920002635 polyurethane Polymers 0.000 claims description 3
- 239000004814 polyurethane Substances 0.000 claims description 3
- 238000009966 trimming Methods 0.000 claims description 2
- 125000000391 vinyl group Chemical group [H]C([*])=C([H])[H] 0.000 claims 1
- 229920002554 vinyl polymer Polymers 0.000 claims 1
- 239000002985 plastic film Substances 0.000 description 3
- 239000011324 bead Substances 0.000 description 2
- 239000002131 composite material Substances 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 238000010137 moulding (plastic) Methods 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- 235000006506 Brasenia schreberi Nutrition 0.000 description 1
- 244000267222 Brasenia schreberi Species 0.000 description 1
- 230000004075 alteration Effects 0.000 description 1
- 230000000712 assembly Effects 0.000 description 1
- 238000000429 assembly Methods 0.000 description 1
- 239000003086 colorant Substances 0.000 description 1
- 229920002457 flexible plastic Polymers 0.000 description 1
- 239000006260 foam Substances 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- JCYWCSGERIELPG-UHFFFAOYSA-N imes Chemical compound CC1=CC(C)=CC(C)=C1N1C=CN(C=2C(=CC(C)=CC=2C)C)[C]1 JCYWCSGERIELPG-UHFFFAOYSA-N 0.000 description 1
- 238000011065 in-situ storage Methods 0.000 description 1
- 238000002347 injection Methods 0.000 description 1
- 239000007924 injection Substances 0.000 description 1
- 238000001746 injection moulding Methods 0.000 description 1
- 239000002991 molded plastic Substances 0.000 description 1
- 239000012778 molding material Substances 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 230000002093 peripheral effect Effects 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 235000014101 wine Nutrition 0.000 description 1
- 239000002023 wood Substances 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/1418—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure
- B29C45/14196—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure the inserts being positioned around an edge of the injected part
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/1418—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure
- B29C45/14196—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure the inserts being positioned around an edge of the injected part
- B29C2045/14204—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure the inserts being positioned around an edge of the injected part the edges formed by an intermediate mould part
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C2045/1486—Details, accessories and auxiliary operations
- B29C2045/1495—Coating undercut inserts
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
- B29L2031/3005—Body finishings
- B29L2031/3041—Trim panels
Abstract
Plastic panels which are useful as automotive interior trim panels, interior door panels and the like decorative and structural panels, are made by a method which provides an underturned edge onto the panel. The method includes positioning blands (30) over top of a mold ring (36). The blanks (30) are secured to the mold ring (36) and the blank (30) is secured to the mold cavity (32) via a vacuum. The two piece mold (60, 34) is mated together and a substrate is injected into the mold cavity (32). The cavity (32) is opened, the ring (36) is lifted and the formed part (10) is removed from the mold.
Description
w0 9sl27604 ~ 1 8 7 0 1 3 r~ c o .
"METHOD FOR FORMING PLASTIC MOLDED PANELS~
BA~KGROUND OF T~TF INVE~TION
This invention relates to a composite molded panel which may be shaped to form an interior door panel or an interior trim panel for a vehicle or to form similar types of panels used for other purposes. It is especially useful in producing vehicle interior doors and trim panels having an undercut edge.
Interior door panels for vehicles are typically made by first forming a preselected size and shape of foundation board made of stiff particle board, flber board or plastic material which is cornmonly called a substrate. Then, one or more cloth-like sheets are fastened to the surface of the substrate. The substrate may also function to support other items, such as window regulator parts, small motors, wiring and the like, which are located upon or within the door. In many vehicles, the interior surfaces of the door panels are dCCu~lLii~ly enhanced by adding inserts upon the panel. The inserts may be in the form of smaller sections or panels which may be formed, for example, of fabric or carpet-like sheets or sheets with heavily textured surfaces or sheets of different surface colors or material.
Typically, the interior door and trim panels of the type described above are assembled out of separate parts which are positioned upon the substrate and fastened together, one by one, to provide a completely assembled panel. This assembly is fastened within the metal or plastic door or within other parts of the interior of the velucle. This technique for r~, 1,.,;,l,. mterior and trim panels is relatively time consuming and expensive.
Moreover, this limits the ability to S~ -r~ y contour or curve the interior surface of the vehicle. For example, it is difficult to provide a curved or contoured foundation board and wos~/27co4 2187013 r~l~o.,,~.~6~ ~
to cover such a curved board. Therefore, vehicle interior door surfaces are relatively flat and other trim surfaces also have limited curvatures.
Thus, this invention relates a plastic molding method for making interior door and trim panels and the like, which may be curved, and which have a duw~ ldly curved undercut edge, at reduced cost and with enbanced decorative AI~IJf~ f c SUMMARY OF THE INVENTION _ _ The invention herein ,~ : , ' ' molding a plastic panel by, first, preparing a thin, fabric flexible plastic sheet which is sized and shaped to form a blank. The blank is positioned within a mold. As the blank is positioned within the mold, the blank is pulled over a mold ring. Next, plastic molding material is placed within the mold and is molded, in situ, to form a relatively rigid plastic molded substrate whose exposed, outer surface, is made up of the composite of the fabric or plastic sheet blank. The blank could also include inserts of different materials and textures which are carried by the blank. Since the substrate is molded in sifu within the thin fabric or plastic sheet blank, otber objects may be f-u~ly molded upon or within the substrate. For example, window parts~ wires, ductwork and the like may be molded within the substl-ate. Alternatively, the substrate may be provided with integral portions that are configured to receive or to mount exterior mPrh~nir~ll parts or trim elements. Thus, this method may Prn~)mirlllly produce, for example, an interior door panel which may have curved portions and which carries separately mounted or integrally formed arm rests or window controls or other items mounted theref n, while providing an enhanced decoMtive ~rrP~r~nrP.
A major object of the invention is to provide an undercut or duwllLu~ d edge. This is ac~ ;l by the mold ring including a ~ut out portion which enables the blank to be _ _ _ _ _ . _, , , .. . .. ... . ...... . ... . . . . . .. ..... _ .. . _ . _ . . .. . . _ wo ss~27604 2 1 8 7 0 1 3 ~"~ C o '`
received in the cut out portion. As the substrate is injccted into the blank, the material fills in behind the blank forcing the blank into the cut out forming the downturned edge. The blank is continuous around the edge and covers the bottom of the edge. The remainder of the blank may be trimmed from the molded panel to provide an undercut on the molded panel, A further object of the invention is to provide a method for rapidly and ecullu~ lly producing vehicle dûor panels and interior trim panels and the like with a minimum of labor and with better, more uniform quality than has previously been possible utilizing the typical panel assembly techniques which have been used in the past for making door interior panels and trim panels.
These and other objects and advantages of the present invention will become apparent UpOI~ ~di~g he ~low descnption o~ _ h ~he atlached d~ wines ~o~ a ~ art w095127604 21 8701 3 P.~ C ~
IF.I~ DESCRIPTION OF THE DRAWINGS
Figure 1 is a perspective view of an automobile interior door panel which ~rhrn~tir~lly illustrates a panel made in accordance with the method described herein.
Figure 2 is a cross sectional view of Figure 1 along Imes 2-2 thereof.
Figure 3 is a perspective, schematic view of a mold assembly in accordance with the present invention.
Figure 4 is a cross sectional view of Figure 3 along lines 4-4 thereof with the blank loaded on the ring.
Figure 5 is a cross sectioral view of Figure 3 along lines 5-5 thereof with the blank loaded on the ring.
Figure 6 is a cross sectional view of the molds in a closed position.
Figure 7 is a perspective view of the molds in an open condition after forming of the part.
DETAILED DESCRIPTION OF THE PREFERRED EMBOMMENT
Figure 1 srh~ ~rir~lly illustrates an example of an interio} door panel 10 for an automobile. The panel 10 is illustrated as being formed with undercut edges. The panel is sized and shaped to flt within a sheet metal door for trimming the interior of the door within the passenger l,VIII~ II Ll~ of the vehicle . The panel may include for illustration purposes, an upper panel insert 12 which may have an interior face formed so as to simulate a wood grain appearance or may be inlaid with some other material. Similarly, a lower insert 14 is positioned m the panel and may be formed of a piled calpet-like matenal or fabric to simulate a carpet or fabric section of the panel or may be an inlay of some other material.
woss/27604 2 ~ 8 7~ ~ 3 r~.,.J~ c~1~
The panel may be provided with various openings or receptacle areas, after the molding is completed, to receive some of the hardware which is typically mounted within a vehicle door. These openings or areas may be cut or punched into the panel. For example, the panel may have a square or oblong openmg 16 to receive a block of switches which operate the window actuating motorsl amd a second round opening 18 which may receive switch for actuating the exterior side view mirrors. Different sized and shaped opening and receptacle areas may be molded in the panel as required.
The interior surface 20 of the panel may include clLlboD~ L~ or may be textured.
These decorated surface rr,nfi~lr~innc may be formed during the molding of the panel door or may be preformed in the sheet or blank utilized in the molding.
As better illustrated in Figure 2, the edge 22 of the panel 10 is undercut. The blank which is utilized to form the interior surface 20 is continuous around the edge 22 on the panel 10. The molding process begins with being provided with a blank 30 to be positioned into the mold cavity. The b~ank 30 may be formed by methods like those disclosed in U.S.
Patent No. 5,091,031, issued February 25, 1992, the ~1,. . ;1;, -l;.1., and drawings of which are herein expressly i~,u~ dLcd by reference. The blank 30 may include inserts or it may be a continuous sheet of material.
The blank 30 is posilioned into the mold cavity 32 ~f mold 34 on top of the ring 36.
The mold 34 is of the vacuum type, as best illustrated in Figure 6. Once the blank 30 is positioned into the mold cavity 32 on the insert 33, the vacuum is activated around the insert 33, securing the blank onto the mold 34. The outer periphery of the blank is then secured onto the ring 36 via pins 40. The periphery of the blank 30 is pulled down on top of the pins 4~ and is secured thereto.
wo9~27604 2 ~ 870 ~ 3 r~ o ~
The rmg 36 is secured to the female mold via plates 42 and 44 which are secured to a hinge 46. Thus, the hinge 46 enables the ring 36 to be positioned within the cavity and to be rotated out of the cavity for removal of the panel.
As can be seen in Figures 4 and 5, the ring 36 includes a cut out portion 50. The cut out portion 50 has a termmal end 52 which forms the edge of the panel 10. As can be seen irl the drawings, the blank 30 is drawn into the cutout to form the undercut on the panel.
After the periphery of the blank 30 is secured to the ring 36, the top mold 60 is closed onto the ring and bottom mold 34. As can be seen in Figure 6, the substrate is injected through the mold 60 and into the mold cavity 34. Generally, polyurethane or any other plastic material or the like is utilized as the substrate and is rnjected into the mold cavity. The substrate is then allowed to cool in the cavity for a desired period of time.
After the substrate has cured and cooled, the top mold 60 is opened. After opening of the mold, the periphery of the blank 30 is removed from the ring 36 and pins 40. The ring is then moved upward away from the mold 32 and the panel 10 is removed from the ring 36.
Upon removal of the panel 10, generally the peripheral blank is cut or removed from the panel to form a finished panel. Thus, by utilizing the ring 36 with its cutout portion, an undercut can be formed at the panel edge.
If necessary, prior to adding the substrate, wiring switches or the like would be positioned onto the mold 60. If such a positioning of the elements is not necessary, the blank would be in a position like that shown in Figure 6. At this position, the molds are mated together. The mold 60 fits into the mold 34 such that there is a gap between the blank and the mold 60. The mold 60 also includes a bore to enable passage of the substrate into cavity 32. If a second layer of less dense foam backing is required, it could be added prior to the substrate either by injection through the male mold or by spraying it onto the blank.
_ _ _ , _ _, _ , _ , _ _ . , . _ _ . _ , _ _ _ wossl27604 2 1 870 1 3 1 I/~J~ c,-A suitable plastic material is injected into the mold cavity for injection molding the panel substrate therein. The mjected plastic material solidifies in the cavity. Alternately, ~IJdllddl,lc plastic beads may be inserted into the mold cavity, either through the ~Jd~ s.,w~ly or it may be placed in the cavity before the mold is closed. The application of suitable heat for the necessary time causes the expandable beads to mold the substrate and to seal it within the caYity. After the plastic solidifies, the mold panel is removed as described above. The mold panel substrate may include mtegral part such as molded brackets, bosses and other separate parts positioned in the interior of the mold cavity. The pd~ .,w~ly:~ or openings or receptacles may also be formed in the panel during molding. By way of an example, an electric motor for operating the windows, or part of a window regulator m~rh~ni~m or wires or switches or heating/air ~ ";-~ channels or the like may be positioned in the panels during molding, as previously stated.
As illustrated in Figure 6, the mold 32 has a vacuum chamber 80 formed beneath it with a hose 82 comnected to a vacuum pump, not shown. Air is sucked along the insert blade 35 from the cavity surface to the vacuum chamber for positioning and registering the blank on the mold cavity.
The methods described above are ~ILi~,ul~llly useful for molding door panels and thereby replacing ~U~ .llLiull~l door panel assemblies which are made up of a number of parts that are fastened together. However, the methods are also useful in forming other types of trim panels for vehicles as well as other types of panels for other uses. For example, an interior dashboard panel may be formed with inserts of various types molded in the surface of the panel. As another example, a molded headliner may be formed for use within the upper part of the passenger Culll~llLIII~,IIL of a vehicle.
w0 95127604 1 8 7 0 1 3 ~ o ~
The molding methods are useful for producing panels made of a variety of materials.
By way of example, the panel substrate may be formed of a substantially rigid, structural polyurethane plastic which is cu~ c;,llly available from various chemical companies. The particular plastic selected will depend upon the cost, availability and the ultimate use.
The overall molded plastic panel is waterproof. Therefore, UUII~ iOlldl water shields that typically are utilized within vehicle doors, for protecting the trim panel from water seepage due to water entering into the door cavity, are UlUl..C~lly and eliminated. This reduces the cost of the overall door assembly :u-~;d.l~ly.
While the above detailed description describes the preferred ..llbodi-llcllL of the present invention, the invention is susceptible to ".~ , variation, and alteration without deviating from the scope and fair meaning of the subjoined claims.
",' " ' ' ' ' ;
"METHOD FOR FORMING PLASTIC MOLDED PANELS~
BA~KGROUND OF T~TF INVE~TION
This invention relates to a composite molded panel which may be shaped to form an interior door panel or an interior trim panel for a vehicle or to form similar types of panels used for other purposes. It is especially useful in producing vehicle interior doors and trim panels having an undercut edge.
Interior door panels for vehicles are typically made by first forming a preselected size and shape of foundation board made of stiff particle board, flber board or plastic material which is cornmonly called a substrate. Then, one or more cloth-like sheets are fastened to the surface of the substrate. The substrate may also function to support other items, such as window regulator parts, small motors, wiring and the like, which are located upon or within the door. In many vehicles, the interior surfaces of the door panels are dCCu~lLii~ly enhanced by adding inserts upon the panel. The inserts may be in the form of smaller sections or panels which may be formed, for example, of fabric or carpet-like sheets or sheets with heavily textured surfaces or sheets of different surface colors or material.
Typically, the interior door and trim panels of the type described above are assembled out of separate parts which are positioned upon the substrate and fastened together, one by one, to provide a completely assembled panel. This assembly is fastened within the metal or plastic door or within other parts of the interior of the velucle. This technique for r~, 1,.,;,l,. mterior and trim panels is relatively time consuming and expensive.
Moreover, this limits the ability to S~ -r~ y contour or curve the interior surface of the vehicle. For example, it is difficult to provide a curved or contoured foundation board and wos~/27co4 2187013 r~l~o.,,~.~6~ ~
to cover such a curved board. Therefore, vehicle interior door surfaces are relatively flat and other trim surfaces also have limited curvatures.
Thus, this invention relates a plastic molding method for making interior door and trim panels and the like, which may be curved, and which have a duw~ ldly curved undercut edge, at reduced cost and with enbanced decorative AI~IJf~ f c SUMMARY OF THE INVENTION _ _ The invention herein ,~ : , ' ' molding a plastic panel by, first, preparing a thin, fabric flexible plastic sheet which is sized and shaped to form a blank. The blank is positioned within a mold. As the blank is positioned within the mold, the blank is pulled over a mold ring. Next, plastic molding material is placed within the mold and is molded, in situ, to form a relatively rigid plastic molded substrate whose exposed, outer surface, is made up of the composite of the fabric or plastic sheet blank. The blank could also include inserts of different materials and textures which are carried by the blank. Since the substrate is molded in sifu within the thin fabric or plastic sheet blank, otber objects may be f-u~ly molded upon or within the substrate. For example, window parts~ wires, ductwork and the like may be molded within the substl-ate. Alternatively, the substrate may be provided with integral portions that are configured to receive or to mount exterior mPrh~nir~ll parts or trim elements. Thus, this method may Prn~)mirlllly produce, for example, an interior door panel which may have curved portions and which carries separately mounted or integrally formed arm rests or window controls or other items mounted theref n, while providing an enhanced decoMtive ~rrP~r~nrP.
A major object of the invention is to provide an undercut or duwllLu~ d edge. This is ac~ ;l by the mold ring including a ~ut out portion which enables the blank to be _ _ _ _ _ . _, , , .. . .. ... . ...... . ... . . . . . .. ..... _ .. . _ . _ . . .. . . _ wo ss~27604 2 1 8 7 0 1 3 ~"~ C o '`
received in the cut out portion. As the substrate is injccted into the blank, the material fills in behind the blank forcing the blank into the cut out forming the downturned edge. The blank is continuous around the edge and covers the bottom of the edge. The remainder of the blank may be trimmed from the molded panel to provide an undercut on the molded panel, A further object of the invention is to provide a method for rapidly and ecullu~ lly producing vehicle dûor panels and interior trim panels and the like with a minimum of labor and with better, more uniform quality than has previously been possible utilizing the typical panel assembly techniques which have been used in the past for making door interior panels and trim panels.
These and other objects and advantages of the present invention will become apparent UpOI~ ~di~g he ~low descnption o~ _ h ~he atlached d~ wines ~o~ a ~ art w095127604 21 8701 3 P.~ C ~
IF.I~ DESCRIPTION OF THE DRAWINGS
Figure 1 is a perspective view of an automobile interior door panel which ~rhrn~tir~lly illustrates a panel made in accordance with the method described herein.
Figure 2 is a cross sectional view of Figure 1 along Imes 2-2 thereof.
Figure 3 is a perspective, schematic view of a mold assembly in accordance with the present invention.
Figure 4 is a cross sectional view of Figure 3 along lines 4-4 thereof with the blank loaded on the ring.
Figure 5 is a cross sectioral view of Figure 3 along lines 5-5 thereof with the blank loaded on the ring.
Figure 6 is a cross sectional view of the molds in a closed position.
Figure 7 is a perspective view of the molds in an open condition after forming of the part.
DETAILED DESCRIPTION OF THE PREFERRED EMBOMMENT
Figure 1 srh~ ~rir~lly illustrates an example of an interio} door panel 10 for an automobile. The panel 10 is illustrated as being formed with undercut edges. The panel is sized and shaped to flt within a sheet metal door for trimming the interior of the door within the passenger l,VIII~ II Ll~ of the vehicle . The panel may include for illustration purposes, an upper panel insert 12 which may have an interior face formed so as to simulate a wood grain appearance or may be inlaid with some other material. Similarly, a lower insert 14 is positioned m the panel and may be formed of a piled calpet-like matenal or fabric to simulate a carpet or fabric section of the panel or may be an inlay of some other material.
woss/27604 2 ~ 8 7~ ~ 3 r~.,.J~ c~1~
The panel may be provided with various openings or receptacle areas, after the molding is completed, to receive some of the hardware which is typically mounted within a vehicle door. These openings or areas may be cut or punched into the panel. For example, the panel may have a square or oblong openmg 16 to receive a block of switches which operate the window actuating motorsl amd a second round opening 18 which may receive switch for actuating the exterior side view mirrors. Different sized and shaped opening and receptacle areas may be molded in the panel as required.
The interior surface 20 of the panel may include clLlboD~ L~ or may be textured.
These decorated surface rr,nfi~lr~innc may be formed during the molding of the panel door or may be preformed in the sheet or blank utilized in the molding.
As better illustrated in Figure 2, the edge 22 of the panel 10 is undercut. The blank which is utilized to form the interior surface 20 is continuous around the edge 22 on the panel 10. The molding process begins with being provided with a blank 30 to be positioned into the mold cavity. The b~ank 30 may be formed by methods like those disclosed in U.S.
Patent No. 5,091,031, issued February 25, 1992, the ~1,. . ;1;, -l;.1., and drawings of which are herein expressly i~,u~ dLcd by reference. The blank 30 may include inserts or it may be a continuous sheet of material.
The blank 30 is posilioned into the mold cavity 32 ~f mold 34 on top of the ring 36.
The mold 34 is of the vacuum type, as best illustrated in Figure 6. Once the blank 30 is positioned into the mold cavity 32 on the insert 33, the vacuum is activated around the insert 33, securing the blank onto the mold 34. The outer periphery of the blank is then secured onto the ring 36 via pins 40. The periphery of the blank 30 is pulled down on top of the pins 4~ and is secured thereto.
wo9~27604 2 ~ 870 ~ 3 r~ o ~
The rmg 36 is secured to the female mold via plates 42 and 44 which are secured to a hinge 46. Thus, the hinge 46 enables the ring 36 to be positioned within the cavity and to be rotated out of the cavity for removal of the panel.
As can be seen in Figures 4 and 5, the ring 36 includes a cut out portion 50. The cut out portion 50 has a termmal end 52 which forms the edge of the panel 10. As can be seen irl the drawings, the blank 30 is drawn into the cutout to form the undercut on the panel.
After the periphery of the blank 30 is secured to the ring 36, the top mold 60 is closed onto the ring and bottom mold 34. As can be seen in Figure 6, the substrate is injected through the mold 60 and into the mold cavity 34. Generally, polyurethane or any other plastic material or the like is utilized as the substrate and is rnjected into the mold cavity. The substrate is then allowed to cool in the cavity for a desired period of time.
After the substrate has cured and cooled, the top mold 60 is opened. After opening of the mold, the periphery of the blank 30 is removed from the ring 36 and pins 40. The ring is then moved upward away from the mold 32 and the panel 10 is removed from the ring 36.
Upon removal of the panel 10, generally the peripheral blank is cut or removed from the panel to form a finished panel. Thus, by utilizing the ring 36 with its cutout portion, an undercut can be formed at the panel edge.
If necessary, prior to adding the substrate, wiring switches or the like would be positioned onto the mold 60. If such a positioning of the elements is not necessary, the blank would be in a position like that shown in Figure 6. At this position, the molds are mated together. The mold 60 fits into the mold 34 such that there is a gap between the blank and the mold 60. The mold 60 also includes a bore to enable passage of the substrate into cavity 32. If a second layer of less dense foam backing is required, it could be added prior to the substrate either by injection through the male mold or by spraying it onto the blank.
_ _ _ , _ _, _ , _ , _ _ . , . _ _ . _ , _ _ _ wossl27604 2 1 870 1 3 1 I/~J~ c,-A suitable plastic material is injected into the mold cavity for injection molding the panel substrate therein. The mjected plastic material solidifies in the cavity. Alternately, ~IJdllddl,lc plastic beads may be inserted into the mold cavity, either through the ~Jd~ s.,w~ly or it may be placed in the cavity before the mold is closed. The application of suitable heat for the necessary time causes the expandable beads to mold the substrate and to seal it within the caYity. After the plastic solidifies, the mold panel is removed as described above. The mold panel substrate may include mtegral part such as molded brackets, bosses and other separate parts positioned in the interior of the mold cavity. The pd~ .,w~ly:~ or openings or receptacles may also be formed in the panel during molding. By way of an example, an electric motor for operating the windows, or part of a window regulator m~rh~ni~m or wires or switches or heating/air ~ ";-~ channels or the like may be positioned in the panels during molding, as previously stated.
As illustrated in Figure 6, the mold 32 has a vacuum chamber 80 formed beneath it with a hose 82 comnected to a vacuum pump, not shown. Air is sucked along the insert blade 35 from the cavity surface to the vacuum chamber for positioning and registering the blank on the mold cavity.
The methods described above are ~ILi~,ul~llly useful for molding door panels and thereby replacing ~U~ .llLiull~l door panel assemblies which are made up of a number of parts that are fastened together. However, the methods are also useful in forming other types of trim panels for vehicles as well as other types of panels for other uses. For example, an interior dashboard panel may be formed with inserts of various types molded in the surface of the panel. As another example, a molded headliner may be formed for use within the upper part of the passenger Culll~llLIII~,IIL of a vehicle.
w0 95127604 1 8 7 0 1 3 ~ o ~
The molding methods are useful for producing panels made of a variety of materials.
By way of example, the panel substrate may be formed of a substantially rigid, structural polyurethane plastic which is cu~ c;,llly available from various chemical companies. The particular plastic selected will depend upon the cost, availability and the ultimate use.
The overall molded plastic panel is waterproof. Therefore, UUII~ iOlldl water shields that typically are utilized within vehicle doors, for protecting the trim panel from water seepage due to water entering into the door cavity, are UlUl..C~lly and eliminated. This reduces the cost of the overall door assembly :u-~;d.l~ly.
While the above detailed description describes the preferred ..llbodi-llcllL of the present invention, the invention is susceptible to ".~ , variation, and alteration without deviating from the scope and fair meaning of the subjoined claims.
",' " ' ' ' ' ;
Claims (10)
1. A method of forming a panel having an undercut edge comprising:
providing a die pair, one of said die pair having a cavity;
positioning a ring including a cut out portion in said cavity;
loading a blank into said cavity over said ring;
closing said die pair together over said blank;
adding a substrate into said cavity onto said blank;
molding said substrate and blank into a panel;
removing said panel from said cavity.
providing a die pair, one of said die pair having a cavity;
positioning a ring including a cut out portion in said cavity;
loading a blank into said cavity over said ring;
closing said die pair together over said blank;
adding a substrate into said cavity onto said blank;
molding said substrate and blank into a panel;
removing said panel from said cavity.
2. The method according to claim 1 and pulling said blank, via a vacuum, against said die cavity.
3. The method according to claim 1 and securing the blank to the ring on pins in the ring.
4. The method according to claim 1 wherein said adding comprises injecting said substrate into said cavity.
5. The method according to claim 1 and trimming excess portion of said blank from said substrate.
6. The method according to claim 1 and lifting said ring from said cavity prior to removing said panel.
7. The method according to claim 1 wherein said blank is a fabric, carpet or a vinyl skin.
8. The method according to claim 1 wherein said substrate is a polyurethane or any other plastic material.
9. The method according to claim 1 and enabling said substrate to cool to a desired temperature in said mold prior to removing said panel.
10. The method according to claim 1 wherein said ring is movably secured with said die pair.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US225,965 | 1994-04-08 | ||
| US08/225,965 US6726872B1 (en) | 1994-04-08 | 1994-04-08 | Method for forming plastic molded panels having an undercut edge |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2187013A1 true CA2187013A1 (en) | 1995-10-19 |
Family
ID=22847005
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002187013A Abandoned CA2187013A1 (en) | 1994-04-08 | 1995-04-07 | Method for forming plastic molded panels |
Country Status (4)
| Country | Link |
|---|---|
| US (1) | US6726872B1 (en) |
| CA (1) | CA2187013A1 (en) |
| MX (1) | MX9604649A (en) |
| WO (1) | WO1995027604A1 (en) |
Families Citing this family (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| IT1315033B1 (en) | 2000-09-05 | 2003-01-27 | G M P Poliuretani Spa | DEVICE FOR THE PRODUCTION OF POLYURETHANE MANUFACTURES, RELATED PROCEDURE AND POLYURETHANE MANUFACTURES SO OBTAINED. |
| EP1302363A1 (en) * | 2001-10-09 | 2003-04-16 | HV Developpement, SARL | Method for producing a floor mat for automotive vehicles, injection mould for carrying out the method and floor mat so obtained |
| ITUD20030028A1 (en) * | 2003-02-05 | 2004-08-06 | G M P Spa | MOLDING EQUIPMENT FOR THE PRODUCTION OF POLYURETHANE PRODUCTS AND RELATED PROCEDURE. |
| US20060265962A1 (en) * | 2005-05-23 | 2006-11-30 | Jay Winborn | Snap-on barrier panels for automobile door panel assemblies |
| US7789179B2 (en) * | 2007-05-03 | 2010-09-07 | International Truck Intellectual Property Company, Llc | Method of compression molding motor vehicle components and parts made therefrom |
| CN106965355A (en) * | 2017-05-12 | 2017-07-21 | 浙江帝仕电子科技有限公司 | A kind of matched moulds forming machine |
| US10464493B2 (en) * | 2017-09-13 | 2019-11-05 | Ford Global Technologies, Llc | Deployable door panel receptacle for vehicles |
Family Cites Families (13)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US3986698A (en) * | 1974-08-22 | 1976-10-19 | Times Mirror Company | Apparatus for molding a curved flexible printing plate |
| US4692199A (en) * | 1985-12-13 | 1987-09-08 | Lear Siegler, Inc. | Method and apparatus for bonding fabric to a foam pad |
| JPS6426420A (en) * | 1987-07-23 | 1989-01-27 | Nissha Printing | Device for injection molding and simultaneous decorating and manufacture of injection-molded and simultaneously decorated product |
| US5401456A (en) * | 1987-10-07 | 1995-03-28 | Formex Manufacturing, Inc. | Method of forming a plastic unit having an outer plastic shell encapsulating a foam core |
| US4793793A (en) * | 1988-03-28 | 1988-12-27 | Davidson Textron Inc. | Apparatus having fluid pressure plastic skin folding means for making foamed articles |
| US4923539A (en) * | 1988-09-16 | 1990-05-08 | Stanztechnik Gmbh R+S | Method and apparatus for manufacturing trim panels including several trim components |
| JP2537668B2 (en) * | 1988-09-19 | 1996-09-25 | 豊田合成株式会社 | Method for manufacturing resin molded products |
| US4944908A (en) * | 1988-10-28 | 1990-07-31 | Eaton Corporation | Method for forming a molded plastic article |
| US5091031A (en) * | 1990-05-02 | 1992-02-25 | Vittorio Strapazzini | Method for forming plastic molded panels with inserts |
| US5209880A (en) * | 1990-07-27 | 1993-05-11 | Neo-Ex Lab. Inc. | Process for making a sun visor by molding a pair of shells and bonding them together |
| JPH04119828A (en) * | 1990-09-11 | 1992-04-21 | Toyoda Gosei Co Ltd | Preparation of foamed base material product having mounting jig |
| DE4030964A1 (en) * | 1990-10-01 | 1992-04-02 | Happich Gmbh Gebr | METHOD FOR PRODUCING A PLASTIC MOLDED PART |
| US5266246A (en) * | 1991-11-19 | 1993-11-30 | Casco Tool & Extrusions, Inc. | Method of forming a molded plastic part |
-
1994
- 1994-04-08 US US08/225,965 patent/US6726872B1/en not_active Expired - Fee Related
-
1995
- 1995-04-07 MX MX9604649A patent/MX9604649A/en active IP Right Grant
- 1995-04-07 WO PCT/US1995/004032 patent/WO1995027604A1/en active Application Filing
- 1995-04-07 CA CA002187013A patent/CA2187013A1/en not_active Abandoned
Also Published As
| Publication number | Publication date |
|---|---|
| MX9604649A (en) | 1997-12-31 |
| WO1995027604A1 (en) | 1995-10-19 |
| US6726872B1 (en) | 2004-04-27 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| FZDE | Discontinued |